Method of constructing a building

ABSTRACT

A building having, at least in part, a domed surface is constructed by erecting side walls supported between vertical columns and then providing two structural roof layers spaced from each other with filler material between these layers. The stuctural layers are made in situ using fluent material which solidifies. The lower layer seves as the mold for the upper layer and means are used to pry the upper layer loose and lift it from the lower layer. The filler material suitably comprises a polymeric plastic compound foamed in situ.

April 2, 1974 R. c. BELL, JR 3,801,685

METHOD OF CONSTRUCTING A BUILDING Filed Oct. 28, 1971 BASE LAYER RELEASELAYER FIRST STRUCTURAL LAYER RELEASE LAYER,

SECOND STRUCTURAL LAYER SPACING STRUCTURAL LAYERS REMOVAL OF RELEASELAYER FILLER QMATERIAL ADDED L IN SPACE PERMANENT ROOFING COAT REMOVALOF BASE LAYER United States Patent 3,801,685 METHOD OF CONSTRUCTING ABUILDING Robert C. Bell, Jr., 528 Main St., New Canaan, Conn. 06840Filed Oct. 28, 1971, Ser. No. 193,278 Int. Cl. E04b 7/08, 7/14; E04d11/02 US. Cl. 264-45 14 Claims ABSTRACT OF THE DISCLOSURE A buildinghaving, at least in part, a domed surface is constructed by erectingside walls supported between vertical columns and then providing twostructural roof layers spaced from each other with filler materialbetween these layers. The structural layers are made in situusing fluentmaterial which solidifies. The lower layer serves as the mold for theupper layer and means are used to pry the upper layer loose and lift itfrom the lower layer. The filler material suitably comprises a polymericplastic compound foamed in situ.

CROSS-REFERENCE TO RELATED APPLICATION This patent application isrelated to my copending application for U.S. Letters Patent entitledMethod of Constructing a Building" Ser. No. 82,308 filed Oct. 20, 1970,now abandoned.

BRIEF SUMMARY OF THE INVENTION My copending patent application describesa method of constructing an economical, practical and attractivebuilding having, at least in part, a curved or domed roof surfaceconstructed in situ. For this purpose an inflated membrane is used whichacts as a base upon which material adapted to harden in situ is laid orsprayed. Material of this type may comprise a mixture of fiber glass andepoxy, plastic resins, concrete and the like which upon solidificationretain the curved shape so that the membrane can be removed and a freestanding structural layer supported only by the side walls of thebuilding is achieved.

The present invention discloses an improvement in that two structurallayers of this type are formed with a filler or insulating materialdisposed between both structural layers for the purpose of providingimproved rigidity and thermal insulation. Moreover, a roof structure ofthe type described hereinafter may be provided with a more permanent andsturdy roofing layer, such as sprayed-on cement, for achieving anextremely rugged, sturdy and permanent structure.

The invention, furthermore, discloses the use of vertical columns whichare readily transportable and erected in situ, thus achieving a simpleand economical construction, yet one which is pleasing in appearance andeconomical and easy to fabricate.

Other features of the present invention will be more clearly apparent byreference to the following description when taken in conjunction withthe accompanying drawmgs.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a tabulation of the stepsfor providing a roof structure in accordance with the present invention;

FIG. 2 is an elevational view, such as the front, of a typical buildingconstructed in accordance with the present invention.

FIG. 3 is a detailed view of a lifting arrangement for spacing twostructural layers which form a part of the roof structure;

FIG. 4 is a detailed view showing an alternative lifting mechanism, and

Patented Apr. 2,, 1974 "ice DETAILED DESCRIPTlION Referring now to thedrawings and FIG. 2 in particular, a typical building or dwelling isshown which comprises a set of spaced vertical columns 12, each columnresting on a concrete pad 14 whose top surface is at ground level, butwhich may be elevated above or recessed below ground level ascircumstances dictate. The space between the columns 12 is occupied byside wall panels 16 which, preferably, are prefabricated and which mayinclude windows as desired. Alternatively, an entire side panel 16 mayform a window which may be fixed or comprise two sections slidablerelative to one another. There may be provided also one or more lintelsand gables 18 and the like in order to provide a pleasing appearancewhich may be varied from dwelling to dwelling. The present design canreadily use prefabricated portions which are erected at the buildingsite with the roof structure constructed in situ.

The roof, in accordance with the present invention, comprises asandwich-type assembly which includes a first structural layer 20, asecond structural layer 22 and filler material 24 filling the spacebetween the layers 20 and 22. In addition, a permanent roofing coat (notshown) may be applied to the top surface of the second structural layer22. As desired, a skylight 26 may be disposed in a cut-out of the roofstructure, or the roof structure may be thinned and made sufficientlylight transmitting so that the desired degree of light entry and lightdiffusion is obtained.

In order to construct the present roof, the columns 12 and side walls 16are erected and the columns 12 are lashed or braced together so as toachieve a reasonably stable side wall structure. To provide the firststructural roof layer 20, see also FIG. 1, a base or mold isconstructed. Flat or gabled areas of the roof to be constructed arecovered with plywood, fiber board or other flat forms and supported orpropped into location. Curved or domed surfaces are covered by an airsupported membrane or balloon which can be made economically from anysuitable paper base material, rubber, plastic, fiber or other aircontaining or inflatable material as described in the copending patentapplication supra.

When the desired mold or base is achieved, it will be advisable to applyto the top of this base a layer of release material, such as a coatingof silicone material, wax or the like in order to provide a parting linealong which this base can be separated and removed after the roofstructure has been completed.

The top surface of the base and release layer is then covered withmaterial which is either fluent or has a liquid constituent in order togive it the property of flowing and solidification in the flowed contourand shape. Material of this type includes fiber glass or polymericplastic resins applied by either the hand lay-up or spray process. Abase of burlap or other fabric will be advisable to provide suflicientstrength and continuity and to give to the base protection from thechemically generated heat. Suitable filler and reinforcement of theplastic resinous material may be achieved by fabric or woven rovings ormats embedded or laminated or chopped and mixed into sprayed or spreadplastic material. One or more of these applications may be requireddepending upon the consistency of the material and the roof area, i.e.strength requirement. After this first structural layer has beenachieved, providing sufficient time for solidification and curing, thisfirst layer is used as a base or mold for a second and very similarlayer.

Before proceeding with the second structural layer, a release coating isapplied once again to the first structural layer. As described above, asilicone release coating, wax or the like is most suitable and exemplaryof many compounds usable for this purpose.

The second structural layer is then prepared substantially as describedbefore in connection with the first structural layer, the material usedmay or may not be exactly identical, however, it will include aconstituent which solidifies in situ. After the second layer is ofsufficient thickness and is properly cured, the second structural layeris lifted from the first structural layer. The second hardened layer canbe pried up from the edges, but more suitably lift screws are used fromthe first structural layer against the inner surface of the juxtaposedsecond structural layer in order to obtain a gradual and more or lesseven lifting. Such lifting aids are located at points in interiorlocations and will assist the separation of the second layer at moreditficult and less accessible places.

FIG. 3 shows a typical lift screw 30 having a handle 32 and beinginserted through the first structural layer 20. A swiveled push plate 34is adapted to engage the underside of the second structural layer 22. Itwill be apparent to those skilled in the art, that this liftingarrangement must be provided in the first structural layer after therelease layer is applied but before the second structural layer isformed. A simpler screw-type lifting arrangement is shown in FIG. 4,using a pushing screw 40.

When the second structural layer has been separated from the firststructural layer and lifted, generally a few inches, it may be suspendedover the first layer by pegs, props, lifting screws as shown, blocks orchocks or other means to provide air spaces or interstices. A chemicalflushing may or may not be required at this time to remove the releasecoating or layer previously applied to the first layer which providedthe parting line between those layers.

The edges between the suspended structural layers are then sealed orblocked to provide an enclosed area or mold or chamber into whichplastic foam or foaming materials are poured or injected. Due regardmust be had for the high temperatures often developed by such chemicalcuring processes and interactions so that the structural layers are notunduly weakened. The plastic foam or foaming materials act as fillermaterial to provide structural strength and thermal insulation. The roofassembly obtained in this manner is then essentially a sandwichconstruction comprising two structural layers, which may be slightlyflexible, with filler material therebetween to provide structuralstrength and rigidity as well as thermal insulation.

As necessary and if desired, a permanent roof layer may then be appliedto the previously provided structure. This layer may include suitablereinforcing bars and portland cement laid on by pouring or spraying, thelatter being known also as the gunite method. Chemical incompatabilitybetween plastic compounds and the concrete (lime) must be investigatedand avoided. This may be accomplished also by using an interveningcoating of asphalt, rubber or other protective material.

Finally, the base material is removed, unless removed previously.

It should be recognized that the weight and thrust of a pitched roofcarries outward as well as downward. The outward thrust must becontained, in the case of large domed surfaces by a constricting ring,and in the case of a pitched fiat or linear area by tie rods, beams orbuttresses. The outward thrust and the consequent engineering problemsare minimized, of course, by the light weight of the roof contoured toprovide a high strength to weight ratio.

A substantial advantage of the first molded structural layer resides inthe fact that once it is created, successive layers can be made usingthe first layer as a mold. The

layers either wholly or in the form of cut sections can be transportedto other sites, placed upon similar side wall structures, sealed alongthe edges and used as a new first structural roof layer. The stepsrecited heretofore are then repeated.

Similarly, the sandwich-type roof structure, numerals 20, 22 and 24, canbe cut into sectional panels and removed from their place of manufactureor old location along with doors, sidewall panels, pillars, lintels,pediments, Windows, skylights, etc. and then can be reassembled,disassembled and reassembled as living requirements and location changesdictate.

The construction of the columns 12 merits special mention. The designprovides for a fluted and somewhat tapered column of poured concrete ofspecial shape as shown in FIG. 6. The core is a round pipe 13 projectingslightly at both ends and of a diameter which can slip and fit into amatching female hole or pipe embedded in a pad in the ground. The columnhas groves or slots into which glass sidewall doors or panels are fittedand caulked. The columns are more diflicult, expensive and subject tomanufacturing defects if they are fluted and/or tapered but this designproduces a more classical and attractive effect. The taper is from thebottom to the top and is not precisely straight. It may bulge or isslightly convex toward the top to provide a better optical effect and toavoid a concave appearance. Suitable reinforcement of the aggregate maybe devised from coiled or round reinforcement screen. Attractivesurfacing of marbleized design may be superimposed. This may be achievedby modern plastic sheet or coating material joined to the columns bysuitable inert materials. The columns are quickly erected by slippingthe lower end of the projecting pipe 13 into the matching post-holes inthe pad 14. Panels between the columns are then slipped into place and aconnecting ring, wire or bar run from the top of each column toadjoining columns around the perimeter of the structure to lash thecolumns in place and to counteract the outward thrust of the pitch ofthe roof. The columns may also be afiixed by cementing them to the pador footing or, if future removal and transference of the house iscontemplated, the column may be seated on a plastic circle or doily orsimilar material to avoid adhesion and then secured merely by a cementcollar, ring or base poured into a frame or mold around the base, whichcollar or base may be subject to easy breakage and subsequent removal asneeded.

The pediments and lintels of the structure shown in the drawing do notcarry structural weight and can be economically and easily designed andcut from standard plastic foam panel sections, or they may be speciallydesigned to size on a mass production basis and speciallyponred, if needbe, where a suitable number of similar structures or units are inproduction.

It is often desirable to have light sources or lighting panels inaddition to transparent sidewalls, skylights or artificial lightingsources. The roof structural layers previously described may be made astransparent or as opaque as the builder may desire, depending on thechoice of plastic, filler, coating, pigments, or other materials whichmay be used. However, there is another method of lighting control whichshould receive consideration, namely the density and character of theair or gas bubbles embedded in foam plastic. Light rays or beamsstriking a transparent or translucent body or surface suffer a prismaticeffect. They tend to be reflected or refracted at an angle to thesurface. In a foam sheet they tend to pass through the body at rightangles to the surface instead of at a direct angle, partly because it isthe shortest distance through the body. Air or gas bubbles givetranslucene to an otherwise transparent sheet. Their density orfrequency can be regulated to give varying degrees of opaqueness ortranslucency. Translucence gives dispersion to a light source. Atranslucent dome tends to focus or direct the light rays toward thecenter of the dome. By reflecting or refracting or focusing or directinglight rays downward and centrally instead of sideways, a translucentroof provides diffuse yet adequate overhead lighting and eliminateslight glare from lower and more distant roof areas which may be withinthe field of vision. Foam panels become opaque if their thickness isincreased much beyond one-half inch with any substantial number orproportion of gas or air bubbles. If translucency is desired andopaqueness avoided, the foam plastic portion of the roof must be keptthin. Of course this causes a proportionate decrease in strength andinsulating qualities of the roof structure.

Changes in lighting and/or thermal control can be achieved if sectionsand/or layers of multiple roof laminates are made removable.Interlocking or fastened sections of a multiple layer roof or an entirelayer of such a roof can be removed and/ or replaced much like stormwindows, depending on whether translucency or additional roof insulationis desired in varying periods of hot or cold weather or seasons of theyear.

It will be apparent to those skilled in the art that I have describedthe construction and a method for providing a house or houses of classicdesign employing modern materials and using components which will enablepersons of moderate skills to put together an attractive doit-yourselfhome at a minimal cost.

What is claimed is:

1. The process of providing a roof comprising in combination:

providing a substantially horizontally positioned base contoured toconform to the underside of said roof;

applying sutlicient material having at least in part a fluent componentadapted to solidfy in situ upon the top surface of said base to provideafter solidification thereof a first layer over said base;

applying after solidification and curing of said first layer upon saidfirst layer suflicient material having at least in part a fluentcomponent adapted to solidify in situ to form after solidificationthereof a second layer over said first layer;

separating and spacing after solidification and curing of said firstlayer from said second layer to provide a space between said layers;

filling the space between said layers with filler material to provide asandwich structural assembly.

2. The process of providing a roof comprising in combination:

providing a substantially horizontally positioned base contoured toconform to the underside of said roof;

applying sufficient material having at least in part a fluent componentadapted to solidify in situ upon the top surface of said base to provideafter solidification thereof a first layer over said base;

applying after solidification and curing of said first layer a layer ofrelease material upon the top surface of said first layer; applying uponsaid layer of release material sufficient material having at least inpart a fluent component adapted to solidify in situ to form aftersolidification thereof a second layer of release material;

separating and spacing after solidification and curing of said secondlayer said first layer from said second layer, said release materialforming substantially the parting line;

sealing the peripheral space between said spaced layers, and

filling the space between said spaced layers with filler material toprovide a sandwich structural assembly.

3. The process as set forth in claim 2, including the steps of spacingsaid second layer from said first layer comprising elevating said secondlayer relative to said first layer and supporting said second layerdistanced from said first layer.

4. The process as set forth in claim 2 and including the step ofsubstantially removing said layer of release material from said firstlayer before filling the space between said first layer and second layerwith filler material.

5. The process as set forth in claim 4, said step of removing said layerof release material comprising a flushing process.

6. The process as set forth in claim 2, said filler material beingplastic foam.

7. The process as set forth in claim 2, said filler material comprisingfluent plastic material adapted to foam and solidify in situ.

8. The process as set forth in claim 2 and including the additional stepof applying a layer of material upon said second layer after fillingsaid space with filler material.

9. The process as set forth in claim 8, said layer of material beingapplied upon said second layer comprising cement.

10. The process as set forth in claim 2, said first layer and secondlayer comprising at least in part fiberglass material.

11. The process, as set forth in claim 2, said first layer and saidsecond layer comprising at least in part polymeric plastic material.

12. The process as set forth in claim 2 and including the further stepof providing a layer of release material on said base prior to applyingsaid material adapted to solidify to said base to provide said firstlayer.

13. The process as set forth in claim 12 and including the step ofseparating said base from said solidified first layer after saidsandwich assembly has been formed, said layer of release materialbetween said base and first layer forming substantially the partingline.

14. The process as set forth in claim 2 and including the additionalsteps of cutting said sandwich structural assembly into portablesections adapted to be reassembled, and reassembling said sections at adifferent site.

References Cited UNITED STATES PATENTS 2,969,544 1/1961 Di Marco et al.264-45 2,008,815 7/1935 Brandenberger et al. 264-30 2,388,701 11/1945Neff 264-32 2,413,243 12/ 1946 Nelf 264-32 2,484,141 10/1949 Alex 264452,705,211 3/1955 De Wyk 264-45 3,219,732 11/1965 Smith 264-45 3,277,21910/1966 Turner 26445 3,292,338 12/1966 MacClarence et al. 264-323,329,750 7/1967 Growald 26445 3,567,812 3/1971 'Sharenow et a1 264-2643,668,287 6/1972 Mackie 264-45 DONALD E. CZAJA, Primary Examiner R. W.GRIFFIN, Assistant Examiner US. Cl. X.R.

